Section 3: Service Manual - JS200, JS140 & JS205

Section 3
Maintenance
Service Manual - JS200, JS140 & JS205
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine
Publication No.
9813/0400-2
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Notes:
3-0 9813/0400-2 3-0

Contents Page No.

Routine Maintenance
Service Requirements ............................................................................... 3-1
Introduction ............................................................................................3-1
Owner/Operator Support .......................................................................3-1
Service/Maintenance Agreements ........................................................3-1
Fit for Purpose Tests for Lifting Equipment ............................................3-2
Obtaining Replacement Parts ................................................................3-2
Health and Safety ...................................................................................... 3-3
Lubricants ..............................................................................................3-3
Battery ...................................................................................................3-5
Service Schedules ..................................................................................... 3-7
Introduction ............................................................................................3-7
How to Use the Service Schedules .......................................................3-7
Calendar Equivalents ............................................................................3-7
Pre Start Cold Checks, Service Points and Fluid Levels .......................3-8
Functional Test and Final Inspection ...................................................3-12
Service Intervals for Attachments ........................................................3-14
Periodic Replacement of Safety Related Components .......................3-15
Fluids, Lubricants and Capacities ............................................................ 3-16
JS205 ..................................................................................................3-16
JS200 ..................................................................................................3-17
JS140 ..................................................................................................3-18
Engine Lubrication Chart .....................................................................3-19
Hydraulic Oil Chart ..............................................................................3-19
Typical Lubrication Chart .....................................................................3-20
Coolant Mixtures .................................................................................3-22
Fuel .....................................................................................................3-23
Tools ........................................................................................................ 3-25
Carrying Tools onto the Machine .........................................................3-25
Locations .............................................................................................3-25
Prepare the Machine for Maintenance .................................................... 3-26
Introduction ..........................................................................................3-26
How to Make the Machine Safe (Excavator Lowered) ........................3-26
Cleaning the Machine .............................................................................. 3-27
Introduction ..........................................................................................3-27
Preparing the Machine for Cleaning ....................................................3-27
Cleaning the Machine ..........................................................................3-28
Cleaning the Tracks .............................................................................3-28
Cleaning the Radiator and Oil Cooler ..................................................3-28
Checking for Damage .............................................................................. 3-29
Check the Machine Body and Structure ..............................................3-29
Check the Seat and Seat Belt .............................................................3-29
Daily Checking ......................................................................................... 3-30
Greasing .................................................................................................. 3-33
General Notes .....................................................................................3-33
Slew Ring Bearing ...............................................................................3-33
Slew Ring Teeth and Slew Pinion ........................................................3-33
Greasing Points ...................................................................................3-34
Electrical System ..................................................................................... 3-36
Battery .................................................................................................3-36
Jump-Starting the Engine ....................................................................3-38
Fuses ...................................................................................................3-39
Fuses (JS 205) ....................................................................................3-41
Bolt and Nut Torque Specifications .......................................................... 3-43
JS140, JS200 & JS205 .......................................................................3-43
3-i 3-i
Contents
Contents Page No.

Engine ..................................................................................................... 3-47
Checking the Oil Level ........................................................................3-47
Changing the Oil and Filter ..................................................................3-47
Changing the Outer Air Filter Element ................................................3-49
Changing the Inner Air Filter Element .................................................3-50
Checking the Fan Belt Tension ............................................................3-51
Checking the Coolant Level ................................................................3-51
Cleaning the Radiator and Oil Cooler ..................................................3-52
Changing The Coolant ........................................................................3-52
Fuel System ............................................................................................. 3-53
Introduction ..........................................................................................3-53
Filling the Tank and Fuel Level Checking ............................................3-53
Petrol ...................................................................................................3-54
Changing the Fuel Filter Elements ......................................................3-55
Draining Fuel Tank Impurities ..............................................................3-55
Draining the Water Separator ..............................................................3-56
Cleaning the Water Separator .............................................................3-56
Bleeding the Fuel System ...................................................................3-57
Hydraulic System ..................................................................................... 3-58
Checking the Fluid Level .....................................................................3-58
Releasing Tank Pressure ....................................................................3-59
Releasing the Hydraulic Pressure .......................................................3-59
Topping-up Fluid Level ........................................................................3-60
Changing the Fluid ..............................................................................3-60
Draining Water and Sediment from the Hydraulic Tank .......................3-61
Cleaning/Changing the Suction Strainer .............................................3-62
Changing the Return Filter ..................................................................3-62
Changing the Plexus Filter ..................................................................3-63
Changing the Air Breather Element .....................................................3-64
Changing the Pilot Oil Filter .................................................................3-65
Changing the Breaker In-line Filter ......................................................3-66
Changing the Drain Line Filter .............................................................3-66
Air Bleeding Procedures ......................................................................3-67
Slew Gearbox .......................................................................................... 3-69
Checking the Slew Gearbox Oil Level .................................................3-69
Changing the Slew Gearbox Oil Level ................................................3-69
Tracks and Running Gear ....................................................................... 3-70
Tracks ..................................................................................................3-70
Running Gear ......................................................................................3-72
Bucket ..................................................................................................... 3-73
Checking/Adjusting For Side Play .......................................................3-73
Fire Extinguisher (If fitted) ....................................................................... 3-74
Troubleshooting ....................................................................................... 3-75
Engine and Related Area ....................................................................3-75
Monitor Display - Fault Messages .......................................................3-78
Operations ...........................................................................................3-80
Hydraulic pump ...................................................................................3-80
Working Attachments ..........................................................................3-81
Travel ...................................................................................................3-82
Slew .....................................................................................................3-83
Hydraulic ram ......................................................................................3-83
3-ii 3-ii
Routine Maintenance
Service Requirements
Introduction Owner/Operator Support

T3-095
Your machine has been designed and built to give JCB together with your Distributor wants you to be
maximum performance, economy and ease of use under a completely satisfied with your new JCB machine. If you do
wide variety of operating conditions. Prior to delivery, your encounter a problem however, you should contact your
machine was inspected both at the Factory and by your Distributor's Service Department who are there to help
Distributor to ensure that it reaches you in optimum you!
condition. To maintain this condition and ensure trouble
free operation it is important that the routine services, as You will have been given the names of the relevant service
specified in this Manual, are carried out by an approved contacts at your Distributor when the machine was
JCB Distributor at the recommended intervals. installed.
This section of the Manual gives full details of the service To get the most from your Distributor please help them to
requirements necessary to maintain your JCB machine at satisfy you by:
peak efficiency.
1 Giving your name, address and telephone number.
A Service Manual for your machine is available from your
JCB Distributor. The Service Manual contains information 2 Quoting your machine model and serial number.
on how to repair, dismantle and assemble your machine
correctly. 3 Date of purchase and hours of work.
It can be seen from the Service Schedules on the following 4 Nature of the problem.
pages that many essential service checks should only be
carried out by a JCB trained specialist. Only JCB Remember, only your JCB Distributor has access to the
Distributor Service Engineers have been trained by JCB to vast resources available at JCB to help support you. In
carry out such specialist tasks, and only JCB Distributor addition, your Distributor is able to offer a variety of
Service Engineers are equipped with the necessary programmes covering Warranty, Fixed Price Servicing,
special tools and test equipment to perform such tasks, Safety Inspections, including weight tests, covering both
thoroughly, safely, accurately and efficiently. legal and insurance requirements.
JCB regularly updates its Distributors advising them of any Service/Maintenance Agreements
product developments, changes in specifications and
procedures. Therefore only a JCB Distributor is fully able To help plan and spread the costs of maintaining your
to maintain and service your machine. machine, we strongly recommend you take advantage of
the many Service and Maintenance Agreements your
A Service Record Sheet or Book is provided which will Distributor can offer. These can be tailor made to meet
enable you to plan your service requirements and keep a your operating conditions, work schedule etc.
service history record. It should be dated, signed and
stamped by your Distributor each time your machine is Please consult your JCB Distributor for details.
serviced.
Remember, if your machine has been correctly

maintained, not only will it give you improved reliability but
its resale value will be greatly enhanced.
1 9813/0400-2 1
Routine Maintenance
Service Requirements
Fit for Purpose Tests for Lifting

Equipment
T3-097
All lifting equipment (for example forks, lifting hooks and

shackles) need regular inspection and testing by a
competent person to ensure they are fit for purpose.
This may be needed every six months or at least annually

in some countries to meet and comply with legislation and
for insurance purposes.
Check with your local JCB distributor for further advice.
Obtaining Replacement Parts

T3-096
If you use non-genuine JCB parts or consumables, then

you can compromise the health and safety of the operator
and cause machine failure
A Parts Book for your machine is available from your JCB

Distributor. The Parts Book will help you identify parts and
order them from your JCB distributor.
Your dealer will need to know the exact model, build and
serial number of your machine. See Identifying Your
Machine (Introduction section).
The data plate also shows the serial numbers of the

engine, transmission and axle(s), where applicable. But
remember if any of these units have been changed, the
serial number on the data plate may be wrong. Check on
the unit itself.
2 9813/0400-2 2
Routine Maintenance
Health and Safety
Health and Safety
Lubricants The collection and disposal of used oil should be in

T3-060_2
accordance with any local regulations. Never pour used
Introduction engine oil into sewers, drains or on the ground.
It is most important that you read and understand this Handling

information and the publications referred to. Make sure all
your colleagues who are concerned with lubricants read it
too.
!MWARNING
Oil
Hygiene Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
JCB lubricants are not a health risk when used properly for contains harmful contaminants which can cause skin
their intended purposes. cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves to
However, excessive or prolonged skin contact can remove prevent skin contact. Wash skin contaminated with oil
the natural fats from your skin, causing dryness and thoroughly in warm soapy water. Do not use petrol,
irritation. diesel fuel or paraffin to clean your skin.
INT-3-2-3
Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with New Oil
fuel contamination.
There are no special precautions needed for the handling
Whenever you are handling oil products you should or use of new oil, beside the normal care and hygiene
maintain good standards of care and personal and plant practices.
hygiene. For details of these precautions we advise you to
read the relevant publications issued by your local health Used Oil
authority, plus the following.
Used engine crankcase lubricants contain harmful
Storage contaminants.
Always keep lubricants out of the reach of children. Here are precautions to protect your health when handling
used engine oil:
Never store lubricants in open or unlabelled containers.
1 Avoid prolonged, excessive or repeated skin contact
with used oil.
Waste Disposal
2 Apply a barrier cream to the skin before handling
!MCAUTION used oil. Note the following when removing engine oil
from skin:
It is illegal to pollute drains, sewers or the ground.
Clean up all spilt fluids and/or lubricants.
a Wash your skin thoroughly with soap and water.
Used fluids and/or lubricants, filters and contaminated
b Using a nail brush will help.
materials must be disposed of in accordance with
local regulations. Use authorised waste disposal sites.
c Use special hand cleansers to help clean dirty
INT-3-2-14 hands.
All waste products should be disposed of in accordance
d Never use petrol, diesel fuel, or paraffin for
with all the relevant regulations.
washing.
3 9813/0400-2 3
Routine Maintenance
Health and Safety
3 Avoid skin contact with oil soaked clothing.
4 Don't keep oily rags in pockets.
5 Wash dirty clothing before re-use.
6 Throw away oil-soaked shoes.
First Aid - Oil
Eyes
In the case of eye contact, flush with water for 15 minutes.

If irritation persists, get medical attention.
Swallowing
If oil is swallowed do not induce vomiting. Get medical

advice.
Skin
In the case of excessive skin contact, wash with soap and

water.
Spillage
Absorb on sand or a locally approved brand of absorbent

granules. Scrape up and remove to a chemical disposal
area.
Fires
!MWARNING
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon dioxide,

dry chemical or foam. Fire fighters should use self
contained breathing apparatus.
7-3-1-3_1
4 9813/0400-2 4
Routine Maintenance
Health and Safety
Battery
T3-061
!MCAUTION
!MWARNING Damaged or spent batteries and any residue from fires
or spillage should be put in a closed acid proof
Batteries give off an explosive gas. Do not smoke receptacle and must be disposed of in accordance
when handling or working on the battery. Keep the with local environmental waste regulations.
battery away from sparks and flames. INT-3-1-12
Battery electrolyte contains sulphuric acid. It can burn

you if it touches your skin or eyes. Wear goggles.
!MWARNING
Handle the battery carefully to prevent spillage. Keep Battery Gases
metallic items (watches, rings, zips etc) away from the Batteries give off explosive gases. Keep flames and
battery terminals. Such items could short the sparks away from the battery. Do not smoke close to
terminals and burn you. the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
Set all switches to OFF before disconnecting and charged. Do not check the battery charge by shorting
connecting the battery. When disconnecting the the terminals with metal; use a hydrometer or
battery, take off the earth (-) lead first. voltmeter.
INT-3-1-8
Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you
have installed the battery in the machine, wait five
minutes before connecting it up.
When reconnecting, fit the positive (+) lead first.

5-3-4-12
!MCAUTION
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14
!MWARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4
!MDANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1_3
5 9813/0400-2 5
Routine Maintenance
Health and Safety
Warning Symbols First Aid - Electrolyte
The following warning symbols may be found on the Do the following if electrolyte:
battery.
Gets into your eyes
Symbol Meaning
Immediately flush with water for 15 minutes, always get
Keep away from children. medical help.
Is swallowed
A289230-1
Do not induce vomiting. Drink large quantities of water or
Shield eyes.
milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.
A289260-1 Gets onto your skin

No smoking, no naked flames, no sparks.
Flush with water, remove affected clothing. Cover burns
with a sterile dressing then get medical help.
A289280
Explosive Gas.
A289250
Battery acid.
A289240
Note operating instructions.
A289270
6 9813/0400-2 6
Routine Maintenance
Service Schedules
Service Schedules
Introduction How to Use the Service Schedules

T3-036-2 T3-012_4
A badly maintained machine is a danger to the operator In the example shown, A shows all service requirements to
and the people working around him. Make sure that the be carried out every 10 hours and B shows the
regular maintenance and lubrication jobs listed in the requirements to be carried out every 500 hours.
service schedules are done to keep the machine in a safe
and efficient working condition. Important: Services should be carried out at either the
hourly interval or calendar interval, whichever occurs first.
!MWARNING Refer to Calendar Equivalents.
Maintenance must be done only by suitably qualified Important: The intervals given in the schedules must not
and competent persons. be exceeded. If the machine is operated under severe
conditions (high temperature, dust, water, etc.), shorten
Before doing any maintenance make sure the machine the intervals.
is safe, it should be correctly parked on level ground.
To prevent anyone starting the engine, remove the

starter key. Disconnect the battery when you are not
using electrical power. If you do not take these
precautions you could be killed or injured.
8-3-1-1
Apart from the daily jobs, the schedules are based on

machine running hours. Keep a regular check on the
hourmeter readings to correctly gauge service intervals.
Do not use a machine which is due for a service. Make
sure any defects found during the regular maintenance
checks are rectified immediately.
795390-1
Calendar Equivalents
Every 10 Hours = Daily

Every 50 Hours = Weekly
Every 250 Hours = Monthly
Every 500 Hours = Three Months
Every 1000 Hours = Six Months
Every 2000 Hours = 1 Year
Every 4000 Hours = 2 Years
Every 5000 Hours = 2 Years 6 Months
7 9813/0400-2 7
Routine Maintenance
Service Schedules
Pre Start Cold Checks, Service Points and Fluid Levels
Operation 10 50 250 500 1000 2000 4000 5000

Engine
Oil level - Check        
Oil and Filter - Change      
Oil Bypass Filter (if fitted) - Change     
Oil - Sample    
Pre Cleaner (if fitted) - Clean      
Air Cleaner Outer Element - Change    
Air Cleaner Inner Element - Change  
Air Cleaner Dust Valve - Check and Clean      
Fuel Level - Check        
Fuel Filter Element - Change      
Secondary Fuel Filter Element - Change     
Fuel Tank - Water and Sediment - Drain       
Lift Pump Strainer (if fitted)(1) - Clean     
Coolant Quality/Level - Check        
Coolant - Change 
Fuel Sedimenter - Drain       
Fuel Sedimenter - Clean       
Fuel Sedimenter - filter - Change     
Fuel Filler Cap - Check and Clean      
Fuel Filler Cap (Dusty conditions) - Check and Clean       
Fan Belt Tension/Condition - Check      
Valve Clearances - Check and Adjust    
Engine Mounting Bolts for Tightness - Check     
Exhaust System Security - Check     
Air Inlet System Security - Check      
Radiator - Clean and Check      
8 9813/0400-2 8
Routine Maintenance
Service Schedules
Operation 10 50 250 500 1000 2000 4000 5000

Transmission
Security of Mounting Bolts and Nuts - Check     
Track Gearbox Oil Level - Check      
Slew Gearbox Oil Level - Check      
Track and Slew Gearbox Oil (1) - Change     
Track and Slew Gearbox Oil - Sample/Change    
Hydraulics
Oil Level - Check        
Oil (biodegradable and non-biodegradable) - Sample     
Oil (biodegradable) Change  
Oil (Non-biodegradable) Change 
Servo Filter Element (1)(2) - Change    
Plexus Filter Element(2) - Change    
Return Filter Element(1)(2) - Change    
Drain Filter Element(1)(2) - Change    
Suction Strainer(1) - Clean     
Suction Strainer - Change  
Cushion Valve Filter (if fitted) - Clean     
Cushion Valve Filter (if fitted) - Change    
Rams - Chrome Condition - Check      
Oil Cooler - Clean     
Tank - Water and Sediment (if fitted) - Drain      
Hydraulic Tank Air Breather - Change    
Auxiliary Circuit Filter Indicator (if using a - Check
rockbreaker)
       
Pump Line Exit Hose - Change 
Boom Ram Hoses - Change 
Dipper Line Ram Hoses - Change 
Bucket Line Ram Hoses - Change 
9 9813/0400-2 9
Routine Maintenance
Service Schedules
Operation 10 50 250 500 1000 2000 4000 5000

Electrics
Battery Electrolyte Level (if applicable) - Check      
Wiring for Chaffing/Routing - Check       
Battery Terminals for Condition and - Check
Tightness
     
Undercarriage
Track Rollers - Check        
Idler Wheels - Check       
Track Plate Condition and Bolt Torque - Check      
Track Tension - Check        
Track Wear - Check      
Bodywork and Cab
All Pins and Bushes (except Boom Base - Grease
and Boom Dipper)
      
Boom/Bucket/Dipper Pivot Pins (if used in - Check and
very wet or severe conditions, except Boom Grease 
Base and Boom Dipper)
Boom Base and Boom Dipper Pivot Pins - Grease    
Bucket Pivot Pins Grease Seals - Check      
Slew Ring Bearing - Grease       
Slew Ring Teeth - Grease       
Door/Window Hinges - Lubricate      
Cab Heater/Air Con Filter - Clean/Change     
Windscreen Washer Fluid Level - Check        
Condition of Paintwork - Check      
Machine Generally - Check and Clean        
Attachments
Engine Speed in Breaker Mode-Compatible - Check
with fitted Breaker.
    
Quick Hitch - Grease        
Optional Equipment
As Required - Check        
10 9813/0400-2 10
Routine Maintenance
Service Schedules
Operation 10 50 250 500 1000 2000 4000 5000

MISC
Visual inspection for broken or loose - Check        
fasteners.
Major component torques(3) - Check       
Visual inspection of structure for damage - Check        
(1) These procedures are only to be carried out after the first 500 hours use of a new machine. Thereafter they are to be
carried out as detailed in the following periodic checks.
(2) If using a breaker, crusher or pulverises, see `Service Intervals for Attachments' after this section.
(3) Tighten the bolts and nuts after the first 50 hours of the running-in stage and every 250 hours thereafter.
11 9813/0400-2 11
Routine Maintenance
Service Schedules
Functional Test and Final Inspection
Operation 10 50 250 500 1000 2000 4000

Engine
Maximum No-Load Speed - Check    
Exhaust Smoke (excessive) - Check       
Coolant System - Leaks - Check     
Stop Control - Operation - Check     
Fuel System - Leaks and Contamination - Check       
All Fuel Hoses - Change 
Transmission
Slew Brake Operation - Check    
Hydraulics
Operation All Services - Check       
Accumulator (engine stopped) - Check    
Hoses and Pipework - Damage/Leaks - Check     
Electrics
Starter Motor - Connections - Check/Clean     
Alternator - Output - Check     
All Electrical Equipment Operation, (e.g.
warning lights, beacon, alarms, horn, wipers - Check       
etc.)
Undercarriage
Track operation - Check       
Bodywork and Cab
Doors and Canopy - Fitment/Leaks - Check    
Seat/Seat Belts - Condition and Security - Check   
Locks - Check    
Seat
Seat and Seat Belts - Condition and Security - Check   
Seat Adjustments - Correct Operation - Check and Grease    
Seat Adjustments - Correctly Setup for - Check       
Operator
12 9813/0400-2 12
Routine Maintenance
Service Schedules
Operation 10 50 250 500 1000 2000 4000

Attachments
Teeth and Side Cutters - Check    
Attachment Circuit Pressure - Check    
Operation - Check    
Optional Equipment
Overload Warning - Check    
Refuel Pump (if fitted) - Check       
Lifting Equipment
Fit for purpose test(1) - Complete   
(1) This may be required every six months or at least annually in some countries to meet and comply with legislation and
for insurance purposes.
13 9813/0400-2 13
Routine Maintenance
Service Schedules
Service Intervals for Attachments Servicing of the hydraulic oil and filters must be done more
frequently according to the percentage of total operating
When using a breaker, crusher or pulveriser, hours involving use of the breaker, crusher or pulverizer.
contamination and degradation of the hydraulic oil occurs When a breaker, crusher or pulverizer is fitted, ensure that
much more quickly than in normal excavating use. If the the oil and filters are changed at the intervals shown in the
machine is used with increasingly degrading oil it can table below.
cause problems in the control valve, premature wear of the
hydraulic pump and damage to the hydraulic system as a The hydraulic oil must be sampled and checked for
whole. contamination and degradation at the intervals shown.
Consult your JCB Distributor who will have the facilities to
do this work and ensure that the hydraulic system is
properly maintained.
Table 1. Service Intervals for Hydraulic Oil and Filters according to Frequency of Breaker, Crusher or Pulverizer
Use
Item Use Frequency
Greater than 75% 50 - 75% 25 - 50% 10 - 25% Less than 10%
10 100 600 10 200 1000 10 300h 1500h 10 600h 3000h 10 800h 4000h
hrs hrs hrs hrs hrs hrs hrs rs rs hrs rs rs hrs rs rs
Hydraulic Oil          
Return Filter(1)     
Suction Filter (1)
         
Drain Filter(1)     
Servo Filter(1)     
Plexus Filter(1)     
Breaker In-Line     
Filter(1)
Hydraulic Oil
Every 200 hrs Every 200 hrs Every 300 hrs Every 600 hrs Every 800 hrs
Sampling
(1) The filters must be changed whenever the period of breaker/crusher/pulverizer use exceeds 100hrs, regardless of the
total number of hours the machine has worked
 Check oil level and top up as required
 Change
 Clean
14 9813/0400-2 14
Routine Maintenance
Service Schedules
Periodic Replacement of Safety Related operation the service life of specific parts, so routinely
replace them as important parts every 2 years.
Components
Routinely replace important parts concerned with safety. It
is difficult to determine by visual inspection or from
Table 2. Fuel System

Important Parts Replacement Interval
Fuel Hose (Fuel Tank - Engine)
Every 2 years or every 4000 hours, whichever comes first.
Fuel Hose (Fuel Filter - Injection Pump)
Table 3. Hydraulic System

Important Parts Replacement Interval
Pump Exit Hose (Pump - Operation Valve)
Boom Ram Line Hose
Every 2 years or every 4000 hours, whichever comes first.
Dipper Ram Line Hose
Bucket Ram Line Hose
If any abnormality is found with any of these parts before described K Table 4. ( T 15). Re-tighten, replace, etc.,
the replacement time, repair or replace as you would do when any abnormality is found.
normally.
Note: Replace O-rings, gaskets at the same time as
When replacing the hoses, if the hose clamps are found to hoses. Contact your JCB distributor for replacement of
be deformed or cracked, replace the clamps at the same safety parts. Carry out inspection of the hydraulic hoses
time as the hoses. and fuel hoses at the routine inspection described
K Table 4. ( T 15).
Regarding hydraulic hoses not included in the routine
replacement of safety parts, carry out the inspection
Table 4.
Inspection Classification Inspection Item
Start-up Inspection Fuel, Hydraulic hose connections, Oil Leakage from caulked parts.
Special Independent Inspection (Monthly Fuel, Hydraulic hose connections, Oil Leakage from caulked parts. Fuel,
Inspection) Hydraulic hose damage (cracks, wear, picking)
Special Independent Inspection (Yearly Fuel, Hydraulic hose connections, Oil Leakage from caulked parts. Fuel,
Inspection) Hydraulic hose interference, squeezing, aging, twisting, damage (cracks,
wear, picking)
15 9813/0400-2 15
Routine Maintenance
Fluids, Lubricants and Capacities
JS205
Item Lubricant International Specification Capacity

Engine K Engine Lubrication 19 litres
Chart ( T 19) (4.2 UK gal)
(5 US gal)
Track Gearbox JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 5 litres
(2 x 1.1 UK gal)
(2 x 1.3 US gal)
Slew Gearbox JCB HD90 Gear Oil API-GL-5, MIL-L-2105 5 litres
(1.1 UK gal)
(1.3 US gal))
Track Rollers and Idler JCB HD90 Gear Oil API-GL-5, MIL-L-2105
Wheel
Recoil Spring Cylinder JCB Special HP Grease Lithium complex (NLGI)
inc.extreme pressure additives
Hydraulic System JCB Hydraulic Fluid 46 ISO VG46 203 litres
(44.64 UK gal)
(53.63 US gal)
Slew Ring
- Bearing JCB Special HP Grease Lithium complex (NLGI) inc. --
extreme pressure additives
- Gear Teeth JCB Special HP Grease Lithium complex (NLGI) inc. 17 kg (37.5 lb)
All Other Grease Points JCB Special HP Grease Lithium complex (NLGI) inc. --
Cooling System JCB HP Coolant/JCB ASTM D - 6210 25.5 litres
Coolant: Ready to Use (5.6 UK gal)
K Coolant
Mixtures ( T 22)
(6.7 US gal)
Fuel Tank K Fuel ( T 23) 343 litres
(75.5 UK gal)
(90.6 US gal)
16 9813/0400-2 16
Routine Maintenance
JS200

Engine K Engine Lubrication 14.2 litres
To 1773331,2053667 Chart ( T 19) (3.1 UK gal)
(4.1 US gal)
From 1773332,2053668 Chart ( T 19) (4.2 UK gal)
(5 US gal)
Track Gearbox JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 5.3 litres
To 1773163,2053475 (2 x 1.1 UK gal)
(2 x 1.4 US gal)
Track Gearbox JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 5 litres
From 1773164,2053476 (2 x 1.1 UK gal)
(2 x 1.3 US gal)
Slew Gearbox JCB HD90 Gear Oil API-GL-5, MIL-L-2105 5 litres
(1.1 UK gal)
(1.3 US gal))
Track Rollers And Idler JCB HD90 Gear Oil API-GL-5, MIL-L-2105
Wheel
Hydraulic System JCB Hydraulic Fluid 46 ISO VG46 203 litres
(44.64 UK gal)
(53.63 US gal)
Slew Ring
Coolant: Ready to Use (5.6 UK gal)
K Coolant
Mixtures ( T 22)
(6.7 US gal)
(75.5 UK gal)
(90.6 US gal)
17 9813/0400-2 17
Routine Maintenance
JS140

Chart ( T 19) (1.97 UK gal)
(2.37 US gal)
Track Gearbox JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2 x 3.5 litres
(2 x 0.77 UK gal)
(2 x 0.92 US gal)
Slew Gearbox JCB HD90 Gear Oil API-GL-5, MIL-L-2105 2.2 litres
(0.5 UK gal)
(0.6 US gal))
Track Rollers And Idler JCB HD90 Gear Oil API-GL-5, MIL-L-2105
Wheel
Hydraulic System JCB Hydraulic Fluid ISO VG46 124 litres
K Hydraulic Oil
Chart ( T 19)
(27.3 UK gal)
(32.8 US gal)
Slew Ring
Coolant: Ready to (4.3 UK gal)
UseK Coolant
Mixtures ( T 22)
(5.2 US gal)
(55.6 UK gal)
(66.7 US gal)
18 9813/0400-2 18
Routine Maintenance
Engine Lubrication Chart
Use according to ambient temperature °C (°F)

-30 (-22) -20 (-4) -10 (14) 0 (32) 10 (50) 20 (68) 30 (86) 40 (104)
JCB SUPER 15W/40 MULTIGRADE ENGINE OIL, API CF4/SG MIL L-2104F
JCB SUPER 10W/30 MULTIGRADE ENGINE OIL, API CF4/SG MIL L-2104F
Hydraulic Oil Chart
Use according to ambient temperature °C (°F)

-30 (-22) -20 (-4) -10 (14) 0 (32) 10 (50) 20 (68) 30 (86) 40 (104)
JCB HYDRAULIC FLUID 32, ISO VG 32
19 9813/0400-2 19
Routine Maintenance
Typical Lubrication Chart P Hydraulic tank air breather

Q Suction strainer
R Hydraulic tank
S Swing ring gear teeth
T Fuel tank
U Slew gearbox
V Boom/arm grease points
W Boom/arm grease points
Table 6. Icon Definitions
Excavator grease
Engine oil change
Engine oil filter change
Engine coolant change
Fig 1.
Engine air filter clean
Table 5. Location Identifier
A Travel gearbox
B Engine oil filter
C Plexus filter Engine air filter change
D Engine oil pan
E Engine cooling system
F Servo oil filter
Transmission oil change
G Fuel filter
H Swing ring bearing
J Air cleaner, outer
K Air cleaner, inner Transmission oil level
L Drain line filter
M Fuel separator
N Hydraulic return filter
20 9813/0400-2 20
Routine Maintenance
Fuel (diesel) When using bio-degradeable oil
When using in wet or severe

Fuel filter change conditions
Hydraulic oil change
Hydraulic tank breather filter change
Hydraulic oil filter change
Hydraulic oil filter clean
Hydraulic oil level
Engine oil level
Fuel tank level
Drain off water/sediment
When using hammer/crusher/

pulveriser
21 9813/0400-2 21
Routine Maintenance
Coolant Mixtures
T3-009_3
Check the strength of the coolant mixture at least once a

year, preferably at the start of the cold period.
Replace the coolant mixture according to the intervals

shown in the machine's Service Schedule.
!MWARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling full strength or diluted
antifreeze.
7-3-4-4_1
You must dilute full strength antifreeze with clean water

before use. Use clean water of no more than a moderate
hardness (pH value 8.5). If this cannot be obtained, use
de-ionized water. For further information advice on water
hardness, contact your local water authority.
The correct concentration of antifreeze protects the engine

against frost damage in winter and provides year round
protection against corrosion.
The protection provided by JCB High Performance

Antifreeze and Inhibitor is shown below.
50% Concentration (Standard)

Protects against damage down to -40 °C (-39 °F)
60% Concentration (Extreme Conditions Only)

Protects against damage down to -56 °C (-68 °F)
Important: Do not exceed a 60% concentration, as the

freezing protection provided reduces beyond this point.
If you use any other brand of antifreeze:
– Ensure that the antifreeze complies with International

Specification ASTM D6210.
– Always read and understand the manufacturer's
instructions.
– Ensure that a corrosion inhibitor is included. Serious
damage to the cooling system can occur if corrosion
inhibitors are not used.
– Ensure that the antifreeze is ethylene glycol based
and does not use Organic Acid Technology (OAT).
22 9813/0400-2 22
Routine Maintenance
Fuel Acceptable Fuel Specification

T3-089
Use good quality diesel fuel to get the correct power and
performance from your engine.
!MCAUTION
The fuel specification below is acceptable, however
Recommended Fuel Specification this fuel may reduce the life of the fuel injection
equipment. The use of this fuel may also affect the
– EN590 Diesel Fuel Types - Auto/Co/C1/C2/C3/C4 engine performance.
GEN-9-3
– BS2869 Class A2
– ASTM D975-91 Class 2-2DA, US DF1, US DF2, US – ASTM D975-91 Class 1-1DA
DFA
– JP7, MIL T38219 XF63
– JIS K2204 (1992) Grades 1, 2, 3, and Special
– NATO F63
Grade 3
Note: Where low sulphur/low aromatic fuels are used it is

Sulphur Content
important that lubricity additives are used. The additives
listed below are advertised as being suitable for bringing !MCAUTION
the lubricity levels of kerosene/low sulphur fuels up to
those of diesel fuels. They have not been tested or A combination of water and sulphur will have a
approved by the engine manufacturer. They should be corrosive chemical effect on fuel injection equipment.
added by your fuel supplier who should understand the It is essential that water is eradicated from the fuel
concentration level necessary. system when high sulphur fuels are used.
ENG-3-2
1 Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%),
specifically for Indian Superior Kerosene (SKO) but High sulphur content can cause engine wear. (High
may be applicable to other fuels. sulphur fuel is not normally found in North America,
Europe or Australia.) If you have to use high sulphur fuel
2 Lubrizol 539N. Dosage (on Swedish low sulphur fuel) you must change the engine oil more frequently.
250 ppm.
Table 7.
3 Paradyne 7505 (from Infineum). Dosage 500 ppm Percentage of sulphur in Oil Change Interval
(0.05%). the fuel (%)
Less than 0.5 Normal
!MCAUTION 0.5 to 1.0 0.75 of normal
Consult your fuel supplier or JCB distributor about the More than 1.0 0.50 of normal
suitability of any fuel you are unsure of.
GEN-9-2 Aviation Kerosene Fuels
Note: Aviation kerosene fuels are not approved and their

use may cause damage to components. Warranty will not
be allowed on any component where damage is found to
have been caused by the use of aviation kerosene.
Low Temperature Fuels
Special winter fuels may be available for engine operation

at temperatures below 0°C (32°F). These fuels have a
lower viscosity. They also limit wax formation in the fuel at
low temperatures. (Wax forming in the fuel can stop the
fuel flowing through the filter.)
23 9813/0400-2 23
Routine Maintenance
Fatty Acid Methyl Ester Fuels as a Replacement
for diesel Fuels
Fuel resources such as Rape Methyl Ester and Soybean

Methyl ester, collectively known as Fatty Acid Methyl
Esters are being used as alternatives and extenders for
mineral oil.
Fatty Acid Methyl Esters must conform to certain

standards to be of acceptable quality, just as mineral oils
do at present.
Consult your JCB distributor for advice about the use of

Fatty Acid Methyl Ester fuels, as improper application may
impair engine performance.
24 9813/0400-2 24
Routine Maintenance
Tools
Tools
Carrying Tools onto the Machine

When you carry tools onto the machine you must maintain B
three points of contact with the machine at all times. Lift
tools onto the machine in intervals if necessary. Place the
tools down before you adjust your grips on the machine.
Do not try to adjust your grips on the machine while holding
tools.
Locations
The machine is equipped with a grease gun (option) and a
remote oil-drain tube attachment.
The grease gun is stowed into position with clips A,

K Fig 2. ( T 25).
The drain tube is stowed into position by its screw thread

B, K Fig 3. ( T 25).
Keep the tools in their stowage positions until they are Fig 3.
needed. The location of the tools will vary dependant on
the machine variant:
Fig 2.
25 9813/0400-2 25
Routine Maintenance
Prepare the Machine for Maintenance
Prepare the Machine for Maintenance
Introduction How to Make the Machine Safe

(Excavator Lowered)
!MWARNING Important: Unless a maintenance procedure instructs you
Maintenance must be done only by suitably qualified differently, you must lower the Excavator.
and competent persons.
1 Park the machine on level, solid ground.
Before doing any maintenance make sure the machine
is safe, it should be correctly parked on level ground. If necessary, refer to K Stopping and Parking the
Machine ( T 52) .
To prevent anyone starting the engine, remove the
starter key. Disconnect the battery when you are not 2 Lower the excavator so the attachment is flat on the
using electrical power. If you do not take these ground as at A.
precautions you could be killed or injured.
8-3-1-1 3 Stop the engine and remove the starter key.
Make the machine safe before you start a maintenance 4 Release tank pressure. K Releasing Tank
procedure. Pressure ( T 59).
Unless a maintenance procedure instructs you differently, 5 Release the hydraulic pressure.
you must lower the Excavator. K How to Make the
Machine Safe (Excavator Lowered) ( T 26). 6 Disconnect the battery to prevent accidental
operation of the engine.
808071-2
Fig 4.
26 9813/0400-2 26
Routine Maintenance
Cleaning the Machine
Introduction
T3-062_2
!MCAUTION
Clean the machine using water and or steam. Do not allow The engine or certain components could be damaged
mud, debris etc. to build upon the machine. by high pressure washing systems; special
precautions must be taken if the engine is to be
Before carrying out any service procedures that require washed using a high pressure system.
components to be removed:
Ensure that the alternator, starter motor and any other
1 Cleaning must be carried out either in the area of electrical components are shielded and not directly
components to be removed or, in the case of major cleaned by the high pressure cleaning system.
work, or work on the fuel system, the whole engine ENG-3-3
and surrounding machine must be cleaned.
Important: Do not aim the water jet directly at bearings, oil
2 When cleaning is complete move the machine away seals or electrical and electronic components such as the
from the wash area, or alternatively, clean away the engine electronic control unit (ECU), alternator or fuel
material washed from the machine. injectors.
Important: When removing components be aware of any Use a low pressure water jet and brush to soak off caked
dirt or debris that may be exposed. Cover any open ports mud or dirt.
and clean away the deposits before proceeding.
Use a pressure washer to remove soft dirt and oil.
Detergents
Note: The machine must always be greased after
Avoid using full strength detergent - always dilute pressure washing or steam cleaning.
detergents as per the manufacturer's recommendations,
otherwise damage to the paint finish may occur. Preparing the Machine for Cleaning
P11-3004
Always adhere to local regulations regarding the disposal 1 Make the machine safe with the excavator lowered.
of debris created from machine cleaning. Refer to Prepare the Machine for Maintenance.
Pressure Washing and Steam Cleaning Important: Stop the engine and allow it to cool for at least
one hour. Do not attempt to clean any part of the engine
!MWARNING while it is running.
When using a steam cleaner, wear safety glasses or a 2 Make sure that all electrical connectors are correctly
face shield as well as protective clothing. Steam can coupled. If connectors are open fit the correct caps or
cause serious personal injury. seal with water proof tape.
13-3-2-10_2
27 9813/0400-2 27
Routine Maintenance
Cleaning the Machine 1 Prepare the Machine
Exterior Park the machine on level ground. Open the bucket

and swing the boom until it is at 90° to the track.
Clean the exterior of the machine using water and/or Lower the bucket to the ground.
steam.
2 Raise the Track
If steam is used the machine must be completely greased
afterwards. K Greasing ( T 33) Operate the boom and dipper controls so that the
track on the side nearest the bucket is lifted up clear
Pay particular attention to the cab windows. Make sure of the ground.
that the radiator grille is not blocked.
3 Rotate the Track
Do not allow mud to build up on the tracks and running
gear. K Tracks and Running Gear ( T 70) When it is safe to do so and you are sure that
everyone is clear of the machine, operate the controls
to rotate the track which is off the ground. Rotate it
Interior
first one way and then the other to shake off the mud.
If necessary, the person outside may use water to get
!MCAUTION the mud off.
Never use water or steam to clean inside the cab. The
4 Inspect the Track
use of water or steam could damage the on-board
computer and render the machine inoperable. Remove
When you have finished, inspect the track rollers,
dirt using a brush or damp cloth.
sprockets and idler wheels for damage and oil leaks.
8-3-4-8
5 Lower the Track

Cleaning the Tracks
Operate the boom and dipper controls to lower the
!MWARNING track to the ground.
If two people are doing this job make sure that the 6 Repeat for the Opposite Track
person operating the controls is a competent
operator. If the wrong control lever is moved, or if the Swing the boom round to the other side and repeat
controls are moved violently, the other person could steps 2 to 5 inclusive for the other track.
be killed or injured.
Cleaning the Radiator and Oil Cooler
If you will be working with another person, make sure
that you both understand what is to be done. Learn A clogged radiator and/or oil cooler can lead to engine
and use the recognised signalling procedures. Do not overheating. Regularly check for a build-up of dirt and
rely on shouting - he will not hear you. debris and if necessary, use compressed air to clean-out
the grille. At the same time check all hoses for damage or
To clean the tracks, you must turn them. When the perishing, and replace if necessary.
tracks are turning, keep clear of rotating parts. Before
starting this job, make sure that you have no loose
clothing (cuffs, ties etc.) which could get caught in
moving parts. Keep people not involved with this job
well away!
MD-3-3-2
28 9813/0400-2 28
Routine Maintenance
Checking for Damage
Checking for Damage
Check the Machine Body and Structure

T3-063_3
Make sure that all guards and protective devices are in

place, attached by their locking devices and free from
damage.
Inspect all steelwork for damage. Note damaged paintwork

for future repair.
Check pivot pins are correctly in place and secured by their

locking devices.
Check steps and handrails are undamaged and secure.
Check for broken, cracked or crazed window glass and

mirrors. Replace damaged items.
Check all lamp lenses for damage.
Check all attachment teeth are undamaged and secure.
Check all safety and instructional labels are in place and

undamaged. Fit new decals where necessary.
Check the Seat and Seat Belt

T3-008_2
!MWARNING
When a seat belt is fitted to your machine replace it
with a new one if it is damaged, if the fabric is worn, or
if the machine has been in an accident. Fit a new seat
belt every three years.
2-3-1-7_1
Inspect the seat belt for signs of fraying and stretching.

Check that the stitching is not loose or damaged. Check
that the buckle assembly is undamaged and works
correctly.
Check that the belt mounting bolts are undamaged,

correctly fitted and tightened.
Check seats are undamaged and secure. Check seat

adjustments for correct operation.
29 9813/0400-2 29
Routine Maintenance
Daily Checking
Daily Checking
It is vital to check certain machine functions and

components daily to ensure that the machine can be
operated safely and efficiently.
1 Prepare the machine K Prepare the Machine for

Maintenance ( T 26).
2 Locate the components to be checked, refer to A

Machine Description, Introduction.
3 Stop the engine, remove the starter key. B
4 Visual check. Check the machine for the following:
a Oil, fuel and coolant leakage.
b Fasteners properly attached.
c Wire breakage, short circuit of cables and terminal

anchorage.
d Oil cleanliness.
e Dust accumulation.
f Engine oil level check and refilling. Check the oil

level before starting the engine and 30 minutes or
more after stopping the engine.Use dipstick A to
check that the oil level is correct. If low, refill with D
engine oil through oil filler port B. Re-check the oil
level about 10-15 minutes after refilling.
!MWARNING C
Hot Coolant
The cooling system is pressurised when the coolant is
hot. Hot coolant will burn you. Make sure the engine is
cool before checking the coolant level or draining the
system.
2-3-3-3
Fig 5.
g Coolant level check and refilling. Check the level 5 Checking after initial start-up
of coolant in the reserve tank C. If low, remove the
reserve tank cap D and refill with coolant. The a Operation of horn and gauges.
correct level is between the FULL and LOW
markings. b Ease of engine starting, abnormal noise and
exhaust gas colour.
c Oil, fuel and coolant leakage.
30 9813/0400-2 30
Routine Maintenance
Daily Checking
b Check to see that the hydraulic oil level is near the
centre of the level gauge C.
c If it is low, remove the filler plug D and refill. Take

care that no dirt or dust gets into the hydraulic oil
when refilling.
d Check the mounting bolts of the fuel and hydraulic

oil tanks for looseness and for fuel and hydraulic
oil leakage.
e Check the mounting bolts of the electrical parts

and battery terminals for looseness and wire
breakage.
Fig 7.
8 Crawler
Fig 6. a Check the shoes E for looseness, wear and

breakage.
6 Fuel level check
b Check the track motor F, upper/lower rollers G, H
Check the fuel level by inspecting the fuel gauge A and idler wheel J for oil leakage and wear.
located on the front of the tank and monitor display. If
low, refill through the fuel filler port B. c Check each mounting bolt for looseness and/or
missing bolts.
!MWARNING Note: The illustration is only typical. The number of upper
Do not remove the hydraulic tank filler cap or cover rollers G and lower rollers H varies according to the
plate when the engine is running. The hydraulic machine model.
system is under pressure. You or others could be
injured. First stop the engine and then release the 9 Boom/Dipper
pressure.
8-3-4-4 Check the high pressure hoses/joints and the
hydraulic rams for oil leakage.
7 Hydraulic oil level check and refilling
10 Accumulator - Check charge
a Follow steps 1-3 of the daily checking procedure
leaving the boom, dipper and bucket positioned a Extend dipper and raise boom.
K Fig 6. ( T 31).
31 9813/0400-2 31
Routine Maintenance
Daily Checking
b Apply emergency stop.
c Operate boom down function.
d Ensure boom lowers to the ground under its own

weight.
11 Bucket and Linkage.
a Check the bucket teeth and side cutter for

looseness, wear and breakage.
b Check the lubrication of the linkage K and

surrounding parts. Check to see if the bucket side
play is within allowable range. (Refer to the
Bucket Section for side play adjustment.)
Fig 8.
32 9813/0400-2 32
Routine Maintenance
Greasing
Greasing
General Notes
For the type of grease to use at each point K Fluids,
Lubricants and Capacities ( T 16).
Do not mix different types of grease. Keep them separate.
!MWARNING
You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove
starter key and disconnect the battery. This will
prevent the engine being started.
8-3-1-3
Slew Ring Bearing

There are two grease nipples on the front of the machine
and one on the front of the ring.
Slew Ring Teeth and Slew Pinion

Ensure slew ring is kept full of grease. Always grease
whenever the machine has been steam-cleaned.
For location of the slew ring gear refer to Identification of

Machine Components.
Fig 9.
1 Make the Machine Safe. Stop the engine and remove
the starter key.
3 Slew the Machine.
2 Grease the Slew Ring.
Start the engine and slew the machine a few
degrees.Stop the engine, remove the starter key and
a Remove the Inspection port cover A (on the lower
apply grease again.
centre section).
Repeat until the whole ring is greased. Check that
b Remove the grease discharge port cover B (on
grease exudes around the entire circumference.
the lower inner side).
4 Refit the Cover.
c Remove contaminated grease.
d Replace the discharge port cover.
e Apply grease to the slew ring via aperture C.
33 9813/0400-2 33
Routine Maintenance
Greasing
Greasing Points
!MWARNING
You will be working close into the machine for these
jobs. Lower the attachments if possible. Remove
starter key and disconnect the battery. This will
prevent the engine being started.
8-3-1-3
Table 8.
Greasing Points No. Hours B
A Boom base 3 1000
C
B Boom ram, eye end pin 2 50
B
C Dipper ram, dump end pin 1 50
D Boom ram, dump end pin 1 50 Fig 11. For JS200, JS205
E Bucket ram to bucket linkage 3 50
F Bucket linkage to bucket pin 1 50
G Dipper to bucket linkage pin 1 50
H Dipper to bucket pin 1 50
J Bucket ram, dump end pin 1 50
K Dipper ram, eye end pin 1 50
L Boom to dipper, connecting pin 1 1000
B
D
Fig 10.
D067660
Fig 12. For JS140
34 9813/0400-2 34
Routine Maintenance
Greasing
Fig 13.
Fig 14.
35 9813/0400-2 35
Routine Maintenance
Electrical System
Electrical System
Battery Battery Disconnection/Replacement
Note: Before commencing work on the battery you must 1 Prepare the Machine. K Prepare the Machine for
read the following procedure in Health and Safety; Maintenance ( T 26).
K Battery ( T 5).
2 Open the battery compartment A.
Checking the Electrolyte Level
a Disconnect the earth terminal first. For
!MCAUTION connection, connect the earth - terminal last.
Do not disconnect the alternator, the battery, or any

part of the charging circuit with the engine running.
8-3-4-1
Maintenance free batteries used in normal temperate

climate applications should not need topping up. However,
in certain conditions (such as prolonged operation at
tropical temperatures or if the alternator overcharges) the
electrolyte level should be checked as described below.
A
Fig 16.
b If removing the battery, remove the nuts B

securing the battery retaining plates. Then
remove both batteries after cable disconnection.
Fig 15. c Replacement is a direct reversal of the removal

procedure.
2 Remove the covers and check the electrolyte level in
each cell. The electrolyte should be 15 mm (0.6 in) 3 Replacement. When replacing the battery do not mix
above the plates. old and new batteries together, they must be replaced
as a pair, as the service life of the new battery will be
!MWARNING shortened.
Do not top the battery up with acid. The electrolyte

could boil out and burn you.
2-3-4-6
3 Top-up if necessary with distilled water or de-ionised

water.
4 Check the Connections. Make sure that the terminals

are tight and clean. Coat them with petroleum jelly to
prevent corrosion.
36 9813/0400-2 36
Routine Maintenance
Electrical System
Terminal Cleaning
1 Prepare the Machine. K Prepare the Machine for

a Remove the terminals K Battery

Disconnection/Replacement ( T 36)
b If the terminal is dirty, clean the post.
Fig 17.
c If the terminal post is corroded and generates

white powder wash the terminal with hot water. If
considerable corrosion is detected, clean with a
wire brush or abrasive paper.
d After cleaning, apply a thin coat of petroleum jelly

to the terminal.
e Re-connect the terminals K Battery

Disconnection/Replacement ( T 36).
37 9813/0400-2 37
Routine Maintenance
Electrical System
Jump-Starting the Engine a Open the side panel to gain access to the
batteries.
!MWARNING b Connect the positive booster cable to the positive

In temperatures below freezing, the battery electrolyte (+) terminal on the front battery of the machine A.
may freeze if the battery is discharged or poorly
charged. Do not use a battery if its electrolyte is c Connect the other end of this cable to the positive
frozen. To prevent the battery electrolyte from (+) terminal of the booster supply B.
freezing, keep the battery at full charge.
d Connect the negative (-) booster cable to a clean
If you try to charge a frozen battery or jump-start and metal part of the machine C away from and below
run the engine, the battery could explode. the battery.
Batteries produce a flammable gas, which is Note: The connection on the machine must be free from
explosive; do not smoke when checking the paint and dirt. Do not use a pivot pin for an earth.
electrolyte levels.
e Connect the other end of this cable to the negative
When jump-starting from another vehicle, make sure (-) terminal on the booster supply.
that the two vehicles do not touch each other. This
prevents any chance of sparks near the battery. 3 Do the Pre-Start Checks.
Switch off all circuits which are not controlled by the 4 Start the Engine.
starter switch.
Run the machine on Redundancy mode for ten
Do not connect the booster (slave) supply directly minutes before switching to computer mode.
across the starter motor.
5 Disconnect the Booster Cables.
Use only sound jump leads with securely attached
connectors. Connect one jump lead at a time. a Disconnect the negative (-) booster cable from the
machine frame earth. Then disconnect it from the
The machine has a negative earth electrical system. booster supply.
Check which battery terminal is positive (+) before
making any connections. Keep metal watch straps and b Disconnect the positive (+) booster cable from the
jewellery away from the jump lead connectors and the positive (+) terminal on the battery. Then
battery terminals - an accidental short could cause disconnect it from the booster supply.
serious burns and damage equipment. Make sure you
know the voltage of the machine. The booster (slave)
supply must not be higher than that of the machine.
Using a higher voltage supply will damage your
machine's electrical system. If you do not know the
voltage of your booster (slave) supply, then contact
your JCB dealer for advice. Do not attempt to jump-
start the engine until you are sure of the voltage of the
booster (slave) supply.
8-2-7-4
1 Set all Switches in the Cab to OFF.
2 Connect the Booster Cables as follows:
Note: These machines have 2 batteries which are Fig 18.

connected in series to give 24 volts. Use a booster supply
of 24 volts.
38 9813/0400-2 38
Routine Maintenance
Electrical System
Fuses
!MCAUTION
Fuses
Always replace fuses with ones of correct ampere
rating to avoid electrical system damage.
8-3-3-5
The electrical circuits are protected by fuses. The fuses are

located under cover A on the right console.
K Fig 19. ( T 39). Open the fuse box cover by releasing
the top fasteners. Label B is fixed to the rear of the cover
for fuse identification. K Fig 20. ( T 40).
If a fuse blows, find out why before fitting a new one.
Fig 19.
39 9813/0400-2 39
Routine Maintenance
Electrical System
WORK LAMP HORN WORK LAMP

RELAY RELAY RELAY
START
RELAY
1 2 3
5A 5A
4 5 6
15A 5A 10A
7 8 9 ESOS
10A 15A 5A RELAY
16 10 11 12
15A 20A 5A
13 14 15
5A 5A 5A
40A
BUZZER
Fig 20. Label (JS200, JS140)
Fuse Circuit(s) Protected Rating

1 Alternator Signal 5A
2 Horn 5A
3 Not used -
4 Work Lamp Option 15A
5 Cabin Lamp 5A
6 Washer 10A
7 Work Light Standard 10A
8 Refuel Pump 15A
9 Battery Feed 5A
10 ESOS 15A
11 Battery 20A
12 Swing Lock 5A
13 Panel Lights 5A
14 Face fan 5A
15 Lever Lock 5A
16 Engine Stop 40A
40 9813/0400-2 40
Routine Maintenance
Electrical System
Fuses (JS 205)
!MCAUTION
Fuses
Always replace fuses with ones of correct ampere
rating to avoid electrical system damage.
8-3-3-5
The electrical circuits are protected by fuses. The fuses

are located under cover F K Fig 21. ( T 41). Open the
fuse box cover by releasing the top fasteners.
If a fuse blows, find out why before fitting a new one.
Fig 21.
41 9813/0400-2 41
Routine Maintenance
Electrical System
D068530-1
Fig 22. Fuses and Relays Label Identification (JS205)
42 9813/0400-2 42
Routine Maintenance
Bolt and Nut Torque Specifications
JS140, JS200 & JS205

Tighten the bolts and nuts according to tables below.
Before and after daily work, check the bolts and nuts for
looseness and for those missing. Tighten if loose and
renew if missing.
Tighten the bolts and nuts after the first 50 hours of the
running-in stage and every 250 hours thereafter.
For tightening torques for the bolts and nuts not listed
K Table 11. ( T 45).
43 9813/0400-2 43
Routine Maintenance
Table 9. JS200, JS205
No. Tightening Point Bolt Diameter Wrench mm Tightening Torque
Nm kgf m lbf ft
1 (1) Travel Motor M16 24 259-288 26.4-29.3 191-212
2 (1) Drive Sprocket M20 30 506-562 51.5-57.3 373-414
3(1) Idler Wheel M16 24 270-310 27.6~31.8 200-230
4(1) Upper (Carrier) Roller M20 30 506 51.6 373
5 (1) Lower (Track) Roller M18 27 259 26.4 191
6 (1) Track Guard M18 27 380-443 38.7-45.1 280-326
7 Shoe Bolt M16 24 640-750 65-76.5 472-553
8 Counter weight M27/M30 41/46 1058-1235/ 108-126/1 780-910/
1335-1545 36-158 985-1140
9(1) Turntable Bearing M20 30 475-554 48.4-56.4 350-408
(Undercarriage)
10(1) Turntable Bearing (Slew M20 30 475-554 48.4-56.4 350-408
Frame)
11(1) Slew Equipment M20 30 562 57.3 414
12 (1) Engine (Engine Mount) M16 24 265-310 27-32 195-230
13 (1) Engine Bracket M10 17 65-75 6.5-7.6 47~55
14 Radiator M12 19 150-175 15-18 108-130
15(1) Hydraulic Pump M10 17 57 5.8 42
16 (1) Hydraulic Oil Tank M16 24 235-285 23.7-29.5 175-210
17 (1) Fuel Tank M16 24 255-285 25.7-29.5 185-210
18 (1) Control Valve M16 24 270-310 27.6-31.8 200-230
19 Battery M10 17 20-30 2.1-2.9 15-21
20 Cab M16 24 127-137 13-14 94-101
21 (1) Rotary Coupling M10 17 20-30 2.1-2.9 15-21
(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed.
44 9813/0400-2 44
Routine Maintenance
Table 10. JS140
No. Tightening Point Bolt Wrench mm Tightening Torque
Diameter
Nm kgf m lbf ft
1 (1) Travel Motor M16 24 259-288 26.4-29.3 191-212
2(1) Drive Sprocket M16 24 220-310 27.6-31.8 200-230
3(1) Idler Wheel M16 24 270-310 27.6-31.8 200-230
4 (1) Upper (Carrier) Roller M20 30 562 57.3 414
5 (1) Lower (Track) Roller M16 24 288 29.36 212
6 (1) Track Guard M16 24 290 29.57 213
7 Shoe Bolt M16 24 363-421 37-42.9 267-310
8 Counter weight M27 41 1700-1900 173-193 1253-1401
9 (1) Turntable Bearing M16 24 259 26.4 191
(Undercarriage)
10(1) Turntable Bearing (Slew M16 24 259 26.4 191
Frame)
11(1) Slew Equipment M16 24 290 29.5 213
12 (1) Engine (Engine Mount) M16 24 290 29.5 213
13 (1) Engine Bracket M16 24 290 29.5 213
14 Radiator M12 19 104 10.6 77
15(1) Hydraulic Pump M10 17 220 22.4 162
16 (1) Hydraulic Oil Tank M16 24 205.9-289.3 20.9-29.5 151.8-213.3
17 (1) Fuel Tank M16 24 250 25.4 184
18 (1) Control Valve M16 24 220 22.4 162
19 Battery M6 10 7 0.7 5
20 Cab M12 19 150-175 15-18 108-130
21 (1) Rotary Coupling M12 19 116 11.8 85
(1) Use JCB Threadlocker and sealer (High Strength) and tighten to the torque listed.
Table 11.
Bolt Diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench mm 10 13 17 19 22 24 27 30
Nm 6.9 15.7 32.3 58.8 98 137.2 196 274.4
Hex bolt Tightening
kgf m 0.7 1.6 3.2 5.9 9.8 13.7 19.6 27.4
Torque
lbf ft 5 12 24 43 72 101 145 202
Wrench mm 5 6 8 10 12 14 16 17
Hex. socket Nm 8.8 21.6 42.1 78.4 117.6 176.4 245 343
head bolt Tightening
kgf m 0.88 2.2 4.2 7.8 11.8 17.6 24.5 34.3
Torque
lbf ft 6.5 16 31 58 87 130 181 253
45 9813/0400-2 45
Routine Maintenance
2 4 10
1 9 3
7
13 6 5
12
13
12
11
8
15
14 16
19
18
17
Fig 23.
46 9813/0400-2 46
Routine Maintenance
Engine
Engine
Checking the Oil Level Changing the Oil and Filter

1 Open the engine compartment.
!MCAUTION
2 Check the oil level. Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
a Locate the dipstick A and remove. Oil should be 2-3-3-2
between the two marks. Add oil if necessary
through filler B. Use only the recommended oil 1 Prepare the machine. K Prepare the Machine for
K Fluids, Lubricants and Capacities ( T 16). Maintenance ( T 26).
Re-check the oil level about 10-15 minutes after
refilling. 2 Let the engine stand until it is warm. Do not check the
oil straight after the engine has stopped, the oil level
b Make sure that the dipstick and filler cap are indicated will actually be lower than it is.
secure.
3 Drain the oil
a Remove the belly plate
b Place an oil collecting container of suitable size

beneath the engine sump drain point.
A
B
C
Fig 24.
Fig 25.
47 9813/0400-2 47
Routine Maintenance
Engine
c Remove the self sealing drain plug outer cover C. a Before starting the engine, turn the engine over
with the Emergency Stop Button ON until the oil
d Fit the self sealing drain kit threaded union (with pressure warning light goes out.
attached pipe) D. Drain sump oil into a suitable
container. b Allow the engine to stand before checking the oil
level K Checking the Oil Level ( T 47).
e Remove the self seal drain kit, clean and refit the
outer cover. (Do not over tighten the cover).
4 Change the filter
a Remove the filter E.
E
Fig 26.
b Clean the filter head.
c Smear the seal on the new filter E with oil.
d Tighten the filter until the seal bites onto the filter
housing.
e Tighten the filter a minimum of one more full turn.
5 Fill the System.
a Fill the engine with new oil through filler B

K Fluids, Lubricants and Capacities ( T 16)).
b Wipe off any spilt oil.
c Check for leaks.
d Make sure the filler cap is correctly refitted.
6 Check for leaks
48 9813/0400-2 48
Routine Maintenance
Engine
Changing the Outer Air Filter Element changed. As a reminder, mark the inner element with a felt
tipped pen each time the outer element is changed.
!MCAUTION 1 Stop the engine.

The outer element must be renewed immediately if the
warning light on the instrument panel illuminates. 2 Press clips A and lift off cover B. Remove outer
element C. Take care not to tap or knock the element.
2-3-3-1
Note: Do not attempt to wash or clean the elements - they 3 Clean the inside of cover B and canister D.
must only be renewed.
4 Insert a new element into the canister, ensure the
Note: Do not run the engine with the dust valve F element is fully seated. Fit cover B with dust valve F
removed. at the bottom. Push the cover firmly into position and
make sure it is secured by clips A.
Note: Change the outer element more frequently if
operating in dusty conditions. A new inner element must 5 Make sure that the wire is connected to the Air Filter
be fitted at least every third time the outer element is Blocked switch.
6 Check all hoses for condition and tightness.
Fig 27.
49 9813/0400-2 49
Routine Maintenance
Engine
Changing the Inner Air Filter Element 3 Lift up pulls J and remove inner element G.
Note: Do not attempt to wash or clean the elements - they 4 Clean the inside of cover B and canister D.
must only be renewed.
5 Carefully insert the new inner element G into the
Note: Do not run the engine with the dust valve F canister. Make sure it seats correctly. Check seal H is
removed. fully seated.
Note: Change the outer element more frequently if 6 Insert a new outer element C into the canister, ensure
operating in dusty conditions. A new inner element must the element is fully seated. Fit cover B with dust valve
be fitted at least every third time the outer element is F at the bottom. Push the cover firmly into position
changed. As a reminder, mark the inner element with a felt and make sure it is secured by clips A.
tipped pen each time the outer element is changed.
7 Make sure that the wire is connected to the Air Filter
1 Stop the engine. Blocked switch.
2 Press clips A and lift off cover B. Remove outer 8 Check all hoses for condition and tightness.
element C.
Fig 28.
50 9813/0400-2 50
Routine Maintenance
Engine
Checking the Fan Belt Tension Checking the Coolant Level
!MWARNING 1 Park the machine on level ground. Stop the engine

and let it cool down. Open the engine compartment.
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
2-3-3-5
!MWARNING
The cooling system is pressurised when the coolant is
Note: Belt tension is automatically maintained and should hot. When you remove the cap, hot coolant can spray
not require adjustment. out and burn you. Make sure that the engine is cool
before checking the coolant level or checking the
1 Prepare the machine. K Prepare the Machine for system.
Maintenance ( T 26). 9-3-3-1_1
2 Check the fan belt tension. Maximum deflection at the 2 Release system pressure. For location of engine
longest point is 9.5-12.7mm. cooling radiator, refer to Identification of Machine
Components. Carefully slacken cap A. Let any
pressure escape. Remove the cap.
Fig 29.
3 Check the Level. The radiator should be filled

completely and the expansion bottle level should be
between the FULL and LOW marks on the bottle C.
Remove the Cap B and Top-up the bottle and radiator
with pre-mixed water/antifreeze if necessary.
K Coolant Mixtures ( T 22).
4 Refit Cap B.
51 9813/0400-2 51
Routine Maintenance
Engine
Changing The Coolant

C
1 Do steps 1 and 2. K Checking the Coolant
Level ( T 51)
2 Drain the system.

B
a Remove the radiator pressure cap.
b Open the radiator drain tap.
c Remove the expansion bottle cap.
d Remove the cylinder block drain plug.
e Let the coolant drain out.
3 Flush the system if necessary. Use clean water.

Fig 30.
4 Refit the drain plug.
5 Refit the Pressure Cap A. Make sure it is tight.
Clean and refit the cylinder block drain plug, making
Note: Check the quality of the antifreeze mixture every sure it is tight. Close the radiator drain tap.
year before the cold weather starts. Change it every two
years. 5 Fill the system.
a Fill via the radiator using the necessary mix of

Cleaning the Radiator and Oil Cooler
clean, soft water and antifreeze. K Coolant
Mixtures ( T 22).
A clogged radiator and/or oil cooler can lead to engine
overheating. Regularly check for a build-up of dirt and
b Fill the expansion bottle until the level in the bottle
debris and if necessary, use compressed air to clean-out
is between the FULL and LOW marks.
the grille. At the same time check all hoses for damage or
perishing, and replace if necessary.
6 Refit the radiator pressure cap. Make sure it is tight.
7 Refit the expansion bottle cap. Make sure it is tight.
8 Check for leaks. Run the engine for a while to raise

the coolant to working temperature and pressure.
Stop the engine. Check for leaks. Re-check the level
in the expansion bottle and top up if necessary.
52 9813/0400-2 52
Routine Maintenance
Fuel System
Fuel System
Introduction Filling the Tank and Fuel Level Checking
!MWARNING Locate the fuel tank K Machine Description ( T 2).
Fuel
Fuel is flammable; keep naked flames away from the
!MWARNING
fuel system. Stop the engine immediately if a fuel leak Diesel Fuel
is suspected. Do not smoke while refuelling or Diesel fuel is flammable; keep naked flames away from
working on the fuel system. Do not refuel with the the fuel system. Do not smoke while refuelling or
engine running. Completely wipe off any spilt fuel working on the fuel system. Do not refuel with the
which could cause a fire. There could be a fire and engine running. There could be a fire and injury if you
injury if you do not follow these precautions. do not follow these precautions.
INT-3-2-2_3 INT-3-2-2_1
!MWARNING 1 Prepare the machine. K Prepare the Machine for

Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of pressurised 2 Filling the tank
fluid and wear protective glasses. If fluid penetrates
your skin, get medical help immediately. a At the end of every working day, fill the tank with
0177 the correct type of fuel. This will prevent overnight
condensation from developing in the fuel tank.
!MCAUTION b We recommend that you lock the fuel cap to
Do not allow dirt to enter the system. Before prevent theft and tampering.
disconnecting any part of the system, thoroughly
clean around the connection. When a component has c After filling, check the fuel level by looking at the
been disconnected, always fit protective caps and fuel gauge, see Monitor Panel in Operation
plugs to prevent dirt ingress. section.
Failure to follow these instructions will lead to dirt

entering the system. Dirt in the system will seriously
damage the systems components and could be
expensive to repair.
INT-3-3-12
!MCAUTION
Running the engine with air in the system could
damage the fuel injection pump. After maintenance,
the system must be bled to remove any air.
2-3-3-11
53 9813/0400-2 53
Routine Maintenance
Fuel System
Petrol
!MWARNING
Petrol
Do not use petrol in this machine. Do not mix petrol
with the diesel fuel; in storage tanks the petrol will rise
to the top and form flammable vapours.
INT-3-1-6
!MWARNING
Mobile Phones
Switch off your mobile phone before entering an area
with a potentially explosive atmosphere. Sparks in
such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when

refuelling the machine.
INT-3-3-9
54 9813/0400-2 54
Routine Maintenance
Fuel System
Changing the Fuel Filter Elements Draining Fuel Tank Impurities
!MWARNING 1 Stop the engine and remove the key.
Fuel 2 Remove screws and take off the cover plate from
Fuel is flammable; keep naked flames away from the below the fuel tank.
fuel system. Stop the engine immediately if a fuel leak
is suspected. Do not smoke while refuelling or 3 Position a suitable container under the drain.
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel Note: The machine is fitted with a magnetic drain plug.
which could cause a fire. There could be a fire and
injury if you do not follow these precautions. 4 Remove the drain plug.
INT-3-2-2_3
5 Drain the water and deposits until clean diesel flows.
1 Prepare the machine. K Prepare the Machine for
Maintenance ( T 26). 6 Fit the drain plug.
!MWARNING
Fuel
A Fuel is flammable; keep naked flames away from the
is suspected. Do not smoke while refuelling or
engine running. Completely wipe off any spilt fuel
injury if you do not follow these precautions.
INT-3-2-2_3
Fig 31.
2 Open the engine compartment. Locate the fuel

filters A.
3 Remove the elements. Using a chain wrench,

unscrew the filter elements A from the filter head.
4 Fit the new elements. Smear the new filter element

sealing rings with fuel oil and hand tighten onto the
filter heads. Use a chain wrench to tighten by a further
2/3.
Bleed the system, K Bleeding the Fuel

System ( T 57).
5 Wipe up any spilt fuel.
55 9813/0400-2 55
Routine Maintenance
Fuel System
Draining the Water Separator Cleaning the Water Separator

The water separator should be drained at least every 50 1 Clamp the fuel inlet hose to prevent loss of fuel.
hours, but more often if necessary.
2 Unscrew the filter B by hand from the filter head C.
1 Stop the engine and remove the key.
3 Wash the filter and O-ring D. Use clean fuel.
2 Drain off any water in the bowl by turning tap A.
4 Screw the filter onto the filter head. Ensure that filter
3 Make sure tap A is turned off and secure. is hand-tight.
5 Remove the clamp from fuel inlet hose.
6 Prime the system. K Bleeding the Fuel

System ( T 57).
C
D
Fig 32.
56 9813/0400-2 56
Routine Maintenance
Fuel System
Bleeding the Fuel System

Air in the fuel system could cause misfiring or failure to
start. Air will enter the system if any part of it is
disconnected or emptied.
Note: Running the engine with air in the system could

damage the fuel injection pump. After maintenance,
remove air from the fuel system as detailed below.
1 Stop the engine. Switch off the engine and remove

the key. A
2 Disconnect the battery. Remove the -ve lead to

chassis. B
3 Open the engine compartment. Locate the priming C
pump.
4 Prepare for bleeding. Loosen the knob A on the Fig 33.

priming pump B by turning it anti-clockwise. The knob
will be lifted by spring pressure.
5 Bleed the system
a Loosen the eye bolt C. Operate the priming pump

knob A until fuel filter is full.
b Next, tighten the eye bolt C, and continue to move

the feed pump handle.
c When the handle becomes difficult to move and

the air is heard being expelled, then air bleeding
is complete.
6 Restore the system to normal. Depress knob A and

turn clockwise to lock into the priming pump B.
!MWARNING
Fuel
Fuel is flammable; keep naked flames away from the
is suspected. Do not smoke while refuelling or
engine running. Completely wipe off any spilt fuel
injury if you do not follow these precautions.
INT-3-2-2_3
Wipe up any spilled fuel. Then start the engine and check
for leaks.
57 9813/0400-2 57
Routine Maintenance
Hydraulic System
Hydraulic System
!MWARNING
The temperature of the hydraulic oil will be high soon
after stopping the engine. Wait until it cools (less than A
40°C) before beginning maintenance.
8-3-4-10
!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2
Checking the Fluid Level

Maintenance ( T 26). Position the machine on level
ground with the bucket and dipper rams fully
extended and the boom lowered to rest the
attachment on the ground, as at A.
B
2 Check the level. Look at the fluid level in the sight
tube B. The level should be between the two marks
on the tube. If the fluid is cloudy, water or air has
entered the system.
Fig 34.
Water or air in the system could damage the hydraulic
pump. Contact your JCB distributor if the fluid is
cloudy.
58 9813/0400-2 58
Routine Maintenance
Hydraulic System
Releasing Tank Pressure Releasing the Hydraulic Pressure
!MWARNING Use the procedure below to release the hydraulic

pressure. You must release the hydraulic pressure before
Do not remove the hydraulic tank filler cap or cover carrying out maintenance on the machine for example.
plate when the engine is running. The hydraulic
system is under pressure. You or others could be 1 Park the machine on hard, level ground and lower the
injured. First stop the engine and then release the attachment.
pressure.
8-3-4-4 2 Stop the engine.
1 Prepare the machine. K Prepare the Machine for 3 Turn the ignition to the 'ON' position.
4 Lower the control lock lever.
2 Release tank pressure.
5 Operate the hand controllers in all directions to
Remove the box nut A of the breather on top of the release pressure in the hydraulic system.
hydraulic oil tank, press the projection and release
the pressure from the tank. 6 Turn the ignition to the 'OFF' position.
On later models, depress rubber boot which replaces 7 Remove the starter key.
box nut A, to release the pressure from the tank.
8 Release the hydraulic oil tank pressure. K Releasing
Tank Pressure ( T 59).
Fig 35.
59 9813/0400-2 59
Routine Maintenance
Hydraulic System
Topping-up Fluid Level Changing the Fluid

1 Prepare the machine. K Prepare the Machine for 1 Prepare the machine. K Prepare the Machine for
Maintenance ( T 26). Maintenance ( T 26).
2 Release tank pressure. K Releasing Tank 2 Release tank pressure. K Releasing Tank
Pressure ( T 59) Pressure ( T 59)
3 Add Fluid.
a Remove plug B.
b Refill oil through the filler port using a suitable

tundish.
c Check the level through the level gauge on the

side of the tank.
d Refit plug B.
Fig 36.
3 Remove the oil.
a Remove cover A and O-ring B.
b Use a pump and discharge the hydraulic oil into

an empty container.
60 9813/0400-2 60
Routine Maintenance
Hydraulic System
c Remove the drain plug C on the bottom of the tank
and drain the remaining oil from the tank.
Note: Have a drain pan ready.
4 Renew the suction strainer D and return filter E.

(K Cleaning/Changing the Suction
Strainer ( T 62) and K Changing the Return
Filter ( T 62)).
5 Tighten the drain plug C securely.
6 Refill the tank with the specified oil to the specified

level. (See Fluid and Lubricants).
7 Seal the System. Install the O-ring B and filler port

cover A.
Note: If the O-ring is damaged, replace it with a new one.
8 Bleed air from the hydraulic components, K Air

Bleeding Procedures ( T 67).
9 Start the engine and run it for 5 minutes without load.

Slowly operate the rams several times and then put
the machine in the hydraulic oil checking position.
10 Check that the hydraulic oil is within the proper range.
Draining Water and Sediment from the

Hydraulic Tank
2 Release tank pressure, K Releasing Tank

Pressure ( T 59).
3 Draining the water and sediment. Carefully loosen the

drain plug C on the bottom of the tank and drain the
sediment and water accumulated at the bottom of the
tank.
Note: Have a drain pan ready. The task is complete when

clean hydraulic fluid flows out.
4 Seal the system. Tighten the drain plug C.
61 9813/0400-2 61
Routine Maintenance
Hydraulic System
Cleaning/Changing the Suction Strainer Changing the Return Filter

2 Locate the suction strainer. See Machine 2 Locate the return filter. See Machine Description in
Description in Introduction section. Introduction section.
3 Release the tank pressure, K Releasing Tank 3 Release Tank Pressure, K Releasing Tank
Pressure ( T 59) Pressure ( T 59)
Fig 37. Fig 38.
4 Remove the suction strainer. 4 Remove the element
a Remove the filler port cover A and O-ring B. a Remove the cover A and O-ring B.
b Remove the suction strainer C from the tank and b Remove spring C, valve D and return filter E from
renew. the tank.
5 Fit the suction strainer. Fitting is a reversal of removal. 5 Fit a new element. Re-assemble in reverse order
When changing the suction strainer, fit a new O-ring using a new filter element E and a new cover O-ring
seal to the filler port cover A and secure the fasteners. B.
6 Check the hydraulic fluid level.
62 9813/0400-2 62
Routine Maintenance
Hydraulic System
Changing the Plexus Filter 4 Remove the plexus filter A.
1 Prepare the machine. K Prepare the Machine for a Close the two filter case cocks B and C by turning
Maintenance ( T 26). them to position X.
2 Locate the plexus filter. See Machine Description in

Introduction section.

Pressure ( T 59)
Fig 40.
b Remove bolts and washers E.
c Slacken the nuts G and insert the screws F to lift

off the cover D.
d Remove the cover D and remove the O-ring H.
e Lift up the Plexus filter A carefully and remove.

Take care not to drop any sediment.
5 Fit a new element
a Slowly immerse the new Plexus filter A. Install the

O-ring H, cover D, nuts G and bolts F and bolts E.
b Torque tighten bolts E to 20Nm (14.75 lbf ft)
c Open the cocks B and C by turning them to

position Y.
6 Priming the plexus filter
a Start the engine and set at low idling, loosen plug

J, then tighten the plug when hydraulic oil flows
out.
b Stop the engine, check the hydraulic oil level and

top-up if low, K Topping-up Fluid Level ( T 60)
Fig 39.
63 9813/0400-2 63
Routine Maintenance
Hydraulic System
Changing the Air Breather Element 5 Refit the filter cover C
1 Prepare the machine. K Prepare the Machine for Adjust the cover so that it fits over the stud, and
Maintenance ( T 26). install in the following order: Seal washer B,
hexagonal nut A and box nut or rubber boot F.
Pressure ( T 59)
3 Locate the air breather element. See Machine

Description in Introduction section.
4 Replace the air breather element
a Remove first the hexagonal nut A, seal washer B

and cover C.
A
B
G C
E
D
Fig 41.
Note: The cover C can only fit in one of two positions

because of the slot G in the cover which locates over a
similar shaped protrusion on the mounting stud.
b Remove the old filter element D together with the

sponge packing E.
c Replace the old filter element D, with a new one.

When installing the new filter element D place the
sponge packing E on the element.
64 9813/0400-2 64
Routine Maintenance
Hydraulic System
Changing the Pilot Oil Filter


Pressure ( T 59)
3 Locate the pilot oil filter. See Machine Description in

4 Dismantle the filter
a Using a wrench on the case, unscrew the filter

case A from the filter head B. Take care not to spill
the oil it contains.
b Remove and discard the element C and O-ring D.
5 Clean the filter base and case. Discard any fluid in the
filter case. Clean out the case and the underside of
the head.
6 Fit new filter components Fig 42.
a Coat the new O-ring D with hydraulic fluid and

locate in the filter head B.
b Coat the seal area of the new element C and

install it in the filter case A.
c Screw the filter case A to the head B and torque

tighten with the wrench.
Table 12. Torque Settings

Item Nm kgf m lbf ft
A 24.4 to 34.3 2.5 to 3.5 18.07 to 25.5
Note: When refitting the pilot filter bowl after changing the
filter element, it is important that the filter bowl is tightened
carefully to avoid damaging the threads in the filter
housing.
65 9813/0400-2 65
Routine Maintenance
Hydraulic System
Changing the Breaker In-line Filter Changing the Drain Line Filter
Note: This filter should be changed at the intervals stated 1 Prepare the machine. K Prepare the Machine for
in Service Schedules or when the visual indicator X has Maintenance ( T 26).
popped up. DO NOT USE THE BREAKER WITH A
BLOCKED FILTER. 2 Release tank pressure, K Releasing Tank
Pressure ( T 59)).
Maintenance ( T 26). 3 Locate the filter. See Machine Description in
Pressure ( T 59)). 4 Unscrew and remove filter A from head B.
3 Locate the filter. See Machine Description in 5 Fit the new filter. Coat the seal of the new filter with
Introduction section. clean hydraulic fluid. Screw the new filter into head B
and tighten. Check and top up the hydraulic fluid
4 Unscrew and remove filter A from head B. level.
5 Fit the new filter. Coat the seal of the new filter with Table 13. Torque Settings
clean hydraulic fluid. Screw the new filter into head B Item Nm kgf m lbf ft
and tighten. Check and top up the hydraulic fluid
A 65 to 68 6.6 to 6.9 47.94 to 50.1
level.
Fig 44.
Fig 43.
66 9813/0400-2 66
Routine Maintenance
Hydraulic System
Air Bleeding Procedures Air Bleeding from Rams
After replacing the hydraulic oil or repairing or replacing If air is not bled from the rams when replaced or repaired,
hydraulic components or removing hydraulic pipes, bleed the piston and/or seals may be damaged.
air from the hydraulic circuit
1 Prepare the machine. Idle the engine at low speed
Bleeding Air from the Hydraulic Pump and extend and retract each ram 5 times, stopping the
ram 100 mm before the end of each stroke.
Maintenance ( T 26). 2 Bleeding. Operate each ram 4 times for the full stroke
to completely bleed the air.
2 Locate the hydraulic pump. See Machine
Description in Introduction section.
3 Temporarily loosen the hose connection or plug at A

to check that oil does not come out of the pump.
4 If oil comes out re-tighten the connection or plug, if it

does not come out remove the hose or plug and pour
hydraulic oil into the pump case through the port.
When oil comes out of the port refit the hose
connection or plug.
5 Run the machine at idle for five minutes.
Fig 45.
67 9813/0400-2 67
Routine Maintenance
Hydraulic System
Air Bleeding from the Slew Motor
If air is not completely bled from the slew motor the motor
bearing or other parts may be damaged.

2 Locate the slew motor. See Machine Description in

3 Checking oil procedure.
a Loosen the air bleeding plug B and check that oil

seeps out from the air bleeding port.
b If no oil comes out, remove the air bleeding plug

B, and fill the motor case with Hydraulic Oil.
c Tighten the air bleeding plug B.
Fig 46.
4 Sealing the system. Idle the engine at low speed and

slowly slew the machine left to right evenly, two times.
68 9813/0400-2 68
Routine Maintenance
Slew Gearbox
Slew Gearbox
Checking the Slew Gearbox Oil Level Changing the Slew Gearbox Oil Level
2 Locate the slew gearbox. See Machine Description 2 Drain the oil.
in Introduction section.
a Remove the drain plug D, located under pump
3 Check the level. compartment belly plate. Allow the oil to drain out.
a Remove the dipstick A, wipe it clean and re-fit. b Wipe the drain plug clean. Remove any metallic
particles.
b Remove the dipstick again and check that the oil
level is within the range B. c Refit the drain plug. Make sure it is tight.
c If necessary, top up through filler port C. 3 Fill with recommended oil through filler port C.
(K Fluids, Lubricants and Capacities ( T 16) K Fluids, Lubricants and Capacities ( T 16).
for oil type).
4 Check the level.
4 Refit the dipstick.
a Remove the dipstick A, wipe it clean and re-fit.
b Remove the dipstick again and check that the oil

level is within the range B.
c If necessary, top up through filler port C.

(K Fluids, Lubricants and Capacities ( T 16)
for oil type).
5 Refit the dipstick.
6 Check for leaks. Run the machine, operate the slew

controls and make sure there are no leaks.
Fig 47.
69 9813/0400-2 69
Routine Maintenance
Tracks and Running Gear
Tracks !MWARNING
Checking/Adjusting the Track Tension When opening the check valve always stand to one
side and loosen a little at a time until grease starts to
1 Prepare the Machine. K Prepare the Machine for come out. If you over-loosen too much grease could
Maintenance ( T 26). spurt out or the valve cover fly out and cause serious
injury.
Position the machine on level ground. Run it 8-3-4-5
backwards and forwards several times. Stop after
running it forwards. !MWARNING
Carry out steps 1 to 3 of Cleaning the Tracks. Block Under no circumstances must the check valve be
up the undercarriage frame. Finish track rotation by dismantled or any attempt made to remove the grease
running the track forwards. Stop the engine and nipple from the check valve.
remove the starter key. 8-3-4-9
!MWARNING If a gap C exists between the idler wheel shaft and

the track frame, you may use pressure to apply the
Raised Machine grease. If there is no gap C after the application of
NEVER position yourself or any part of your body grease, then the necessary repairs must be carried
under a raised machine which is not properly out by your JCB distributor.
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1
2 Check the Tension.
Measure gap A in line with the third roller from the

front and between the lower surface of the track frame
and the upper surface of the shoe. The dimension
should be 275-295 mm for hard ground conditions.
For operation on soft sand or sticky mud it should be
340-360mm.
3 Adjust the Track Tension.
Adjustment is made by either injecting or releasing

grease from the check valve B. Inject grease to
reduce the gap (increase the tension) or open to
release grease and increase the gap.
Fig 48.
Note: Excessive tension can cause the track rail to wear

the drive rollers and sprocket, insufficient tension can
cause wear to the drive sprocket and track rail.
70 9813/0400-2 70
Routine Maintenance
4 Lower the Track. Track Plate Inspection
Remove the blocks from beneath the undercarriage 1 Prepare the machine. K Prepare the Machine for
and lower the track to the ground using the boom and Maintenance ( T 26).
dipper controls.
Note: If a shoe bolt is used when it is loose, it may be
5 Repeat for the Opposite Track. broken. Immediately tighten the shoe bolts whenever they
are found to be loose.
Slew the boom round to the other side and repeat
steps 1 to 4 above. 2 Check and Tighten.
Checking Rollers and Idler Wheels for Oil Leaks
1 Prepare the Machine. K Prepare the Machine for

Carry out steps 1 to 3 of Cleaning the Tracks. Block

up the undercarriage frame.
!MWARNING
Raised Machine
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1
2 Look for Oil Leaks. Fig 49.
Check the top and bottom rollers and the idler wheels Torque tighten the bolts in the sequence shown and
for oil leaks. If leaks are found contact your JCB check that the nuts and shoe are closely fitted to the
distributor for service. link joining surface. K Bolt and Nut Torque
Specifications ( T 43).
!MCAUTION 3 Repeat the Procedure.

Do not run the machine if you discover oil leaks in the
top or bottom rollers or idler wheels. Failure to rectify a Start the engine and move the machine forwards
such leaks could cause damage to the machine. or backward. Stop the engine.
8-3-4-6
b Repeat the above procedure until the whole track
3 Lower the Track. is tightened.
Remove the blocks from beneath the undercarriage

and lower the track to the ground using the boom and
dipper controls.
4 Repeat for the Opposite Track.
Slew the boom to the other side and repeat steps 1 to

3 above.
71 9813/0400-2 71
Routine Maintenance
Running Gear !MCAUTION

Checking the Track Gearbox Oil Level Oil will gush from the hole when the drain plug is
removed. Keep to one side when you remove the plug.
1 Prepare the machine. K Prepare the Machine for 2-3-4-2
b Remove filler/level plug A and drain plug B. Allow
Position the machine on level ground with the level the oil to drain out.
and drain plugs as illustrated K Fig 50. ( T 72).
c Wipe the plugs clean. Make sure you remove all
metal particles.
d Wrap seal tape on the drain plug B and refit.
3 Fill with new oil for oil type and volume. K Fluids,
Lubricants and Capacities ( T 16) .
a Pour new oil through filler/level plug A until oil

runs out of plug A.
b Check the condition of the o-ring, renew if it is

damaged. Refit filler/level plug.
4 Change the oil on the other side.
Repeat steps 1 to 3.
Fig 50. 5 Check for Leaks.
2 Check the level on one side. Run the machine, operate the tracking controls and
then make sure there are no leaks.
Clean the area around filler/level plug A and remove
it. Oil should be level with plug A. Top up through plug
A if necessary for oil types. K Fluids, Lubricants
and Capacities ( T 16)
3 Clean and refit the plug. Make sure it is tight.
4 Check the level on the other side.
Repeat steps 1 to 3.
Changing the Track Gearbox Oil
1 Prepare the machine. K Checking the Track

Gearbox Oil Level ( T 72)
2 Drain the oil on one side.
a Place a container below the drain plug to catch

the oil. The container must be large enough to
hold the maximum gearbox capacity. K Fluids,
Lubricants and Capacities ( T 16)
72 9813/0400-2 72
Routine Maintenance
Bucket
Bucket
Checking/Adjusting For Side Play 2 Measure the Clearance at C.
It is possible to compensate for lateral wear which leads to The clearance should be approximately 0.8 mm
sideways play of the bucket. Regular use of this K Fig 51. ( T 73).
compensating facility leads to less wear on the bucket
swivel pin A and the dipper bushes B. 3 Check the clearance.
Fig 51.

JS03353
Fig 52.
Position the machine on level ground. Set the bucket

as shown K Fig 52. ( T 73). Turn it slightly to the left
and position it so that the arm end is pressed to the
side which is not to be adjusted.
73 9813/0400-2 73
Routine Maintenance
Fire Extinguisher (If fitted)
Fire Extinguisher (If fitted)
The fire extinguisher should be inspected daily.
!MWARNING
Do not use the fire extinguisher in a confined space.
Make sure that the area is well ventilated during and
after using the fire extinguisher.
4-2-3-1
The fire extinguisher is located in the cab behind the

drivers seat at A. Ensure the extinguisher is only used as
directed on the canister.
Fig 53.
!MWARNING
After any use, the extinguisher should be replaced or
serviced.
4-2-3-2
74 9813/0400-2 74
Routine Maintenance
Troubleshooting
Troubleshooting
To extend the service life and improve the operation of the If trouble occurs, search for the cause in the items below
machine, daily inspection and lubrication are necessary as and make adjustments, repairs, etc. as necessary. If the
well as immediately isolating any problem found and cause cannot be isolated, contact your JCB distributor.
dealing with it. If the machine is operated with the problem
uncorrected, it may lead to larger trouble and possibly to a
big accident.
Engine and Related Area

Table 14. Engine does not start
Cause Remedy
Defective starter switch Connect, repair connection
Defective rotation of starter (Starter rotates slowly) Discharged battery, starter problems, contaminated or loose
wiring connection
Improper viscosity of engine oil Inspect and replace as necessary
Excessive cooling of engine (Cold weather) Preheat with air heater. Warm up the coolant (add hot water)
Possible seizure in engine Repair(1)
Incomplete air bleeding of fuel system Completely bleed air
No fuel in fuel tank Refill
Fuel quality unsuitable Inspect and replace as necessary
Fuel filter clogged Clean or replace
Low compression Repair(1)
Defective fuel injection system Repair(1)
Table 15. Engine stops during operation

Cause Remedy
No fuel in fuel tank Refill
Fuel filter clogged Clean and replace
Air is mixed in the fuel system Re-tighten fuel pipe connections and bleed system
Table 16. Low oil pressure

Cause Remedy
Low oil Refill
Defective oil pressure switch Replace(1)
Oil filter clogged Replace element
Low oil viscosity Replace with oil of viscosity matching temperature
Improper operation of oil pump Replace parts(1)
Oil leakage at connections Tighten connections
75 9813/0400-2 75
Routine Maintenance
Troubleshooting
Table 17. Exhaust gas from engine is white or blue
Cause Remedy
Excessive oil consumption Disassemble and repair, replace parts(1)
Excessively low oil viscosity Replace with correct oil
Excessive cooling by radiator Adjust
Improper fuel injection timing Adjust or replace if necessary(1)
Low compression Disassemble and repair, replace parts(1)
Table 18. Exhaust gas from engine is black or dark grey

Cause Remedy
Improper fuel Replace with correct fuel
Improper valve clearance Adjust
Defective fuel injection pump Adjust or replace if necessary(1)
Insufficient air intake (air cleaner clogged) Clean or replace the element
Table 19. Excessive fuel consumption

Cause Remedy
Defective fuel injection pump Replace(1)
Improper spray from fuel injection nozzle Replace(1)
Improper fuel injection timing Adjust or replace if necessary(1)
Improper fuel Replace with correct fuel
Insufficient air intake Clean or replace element
Table 20. Excessive engine oil consumption

Cause Remedy
Excessive oil Drain oil to proper level
Low oil viscosity Replace with oil of viscosity matching temperature
Oil leakage Re-tighten and replace parts if necessary
Worn cylinder piston rings Disassemble and repair, replace parts(1)
Table 21. Abnormal noise (fuel or mechanical)

Cause Remedy
Bad fuel Replace
Damage inside muffler Replace
76 9813/0400-2 76
Routine Maintenance
Troubleshooting
Table 22. Engine overheating (water temperature reads too high)
Cause Remedy
Low coolant Refill
Water leakage Repair
Elongated or oil dirtied belt Clean or replace
Defective radiator Repair or replace(1)
Broken fan Replace(1)
Incorrect mixture of anti-freeze solution Replace
Defective thermostat Replace(1)
Defective water pump Replace(1)
Defective water sensor Replace(1)
Table 23. Defective battery charge

Cause Remedy
Improper belt tension Adjust
Wiring trouble Repair
Defective battery Replace
Defective regulator Replace(1)
Defective alternator Replace(1)
(1) Indicates jobs which should be done by specialist.
77 9813/0400-2 77
Routine Maintenance
Troubleshooting
Monitor Display - Fault Messages

Note: For further information refer to Monitor Panel.
Table 24. Water and Hydraulic oil temperature

Message Cause Remedy
WATER TEMP Water leakage Repair
Belt elongation, soiled with oil Clean or replace
Defective radiator Repair or replace(1)
Broken fan Replace(1)
Improper anti-freeze mixture Replace
Defective thermostat Replace(1)
Defective water pump Replace(1)
Dirty oil cooler (clogged) Clean
Dirty radiator (clogged) Clean
Defective dust protection net (clogged) Clean
HYD TEMP Defective monitor Replace(1)
Table 25. Low oil pressure

OIL PRESS Low Engine oil Refill
Oil leakage at connections Repair
Defective engine oil pressure sensor Replace(1)
Engine oil viscosity low Replace with oil of viscosity matching the
temperature
Defective engine oil pump Adjust, clean, replace(1)
Defective monitor Replace(1)
Table 26. Air filter

AIR FILTER Air filter element clogged Clean, replace
Intake system clogged, foreign matter Clean
inside.
78 9813/0400-2 78
Routine Maintenance
Troubleshooting
Table 27. Alternator
ALTERNATOR Belt tension Adjust
Wiring fault Repair
Defective battery Replace
Defective regulator Replace (1)
Defective alternator Repair or replace(1)
Table 28. Low coolant

COOLANT LOW Coolant low Refill
Defective sensor Replace(1)
(1) Indicates jobs which should be done by a specialist
79 9813/0400-2 79
Routine Maintenance
Troubleshooting
Operations
Table 29. Operating controls hard to operate
Cause Remedy
Foreign matter caught on control valve spool Wash the control valve(1)
Valve sticking Repair or replace valve assembly(1)
Improper lubrication of lever link Grease
Lever link seizure Grease
(1) Indicates jobs which should be done by a specialist.
Hydraulic pump
Table 30. Oil not delivered by oil pump
Cause Remedy
Low hydraulic oil Refill
Clogged suction filter Repair
Table 31. Hydraulic pump does not build pressure

Cause Remedy
Oil leakage inside hydraulic pump Replace hydraulic pump(1)
Air inside the hydraulic pump Refill oil or check hose on suction side
Main relief valve pressure set too low Adjust pressure(1)
Table 32. Abnormal noise from hydraulic pump

Cause Remedy
Cavitation resulting from deformed hose on the suction side Replace filter, replace hydraulic oil if dirty
or suction filter clogged
Joint of the suction side is loose or hydraulic oil is low and Re-tighten or grease the joints. Check that oil is filled to
air is being sucked in proper level inside casing
Cavitation resulting from excessively high viscosity of Replace with hydraulic oil of suitable viscosity
hydraulic oil
Table 33. Oil leakage from hydraulic pump

Cause Remedy
Defective seal in hydraulic pump Replace seal or hydraulic pump(1)
80 9813/0400-2 80
Routine Maintenance
Troubleshooting
Working Attachments
Table 34. Overall low power
Cause Remedy
Insufficient engine output Refer to Engine Service Manual
Function drops due to wear of hydraulic pump Replace hydraulic pump(1)
Defective main relief valve Adjust the pressure or replace(1)
Low hydraulic oil Refill
Viscosity of hydraulic oil incorrect Replace with hydraulic oil of proper viscosity
Suction filter clogged Replace suction filter
Table 35. Defective operations

Cause Remedy
Hydraulic pump broken Replace hydraulic pump(1)
Hydraulic oil low Replace suction filter
Table 36. Insufficient work power

Cause Remedy
Set pressure for main or port relief valve is low or incorrect Adjust pressure or replace relief valve(1)
Damaged hydraulic ram seals Replace hydraulic ram seals(1)
Damaged hydraulic ram, cylinder Replace hydraulic ram/cylinder or the assembly(1)
Table 37. Attachment sinks down

Cause Remedy
Damaged hydraulic ram seals Replace hydraulic ram seals(1)
Damaged hydraulic ram, cylinder Replace hydraulic ram/cylinder or the assembly(1)
Oil leakage inside control valve Repair valve assembly, replace(1)
Oil leakage inside holding valve Repair valve assembly, replace(1)
Table 38. Abnormal noise from joints of the attachment

Cause Remedy
Insufficient grease Grease
Connecting pin seizure Replace the bushing and/or pin
81 9813/0400-2 81
Routine Maintenance
Troubleshooting
Travel
Table 39. Insufficient travel force
Cause Remedy
Pressure setting for main relief valve is too low Adjust the pressure(1)
Defective counterbalance valve Replace the counterbalance valve(1)
Performance reduction of travel motor Replace travel motor(1)
Swivel joint packing damage Replace swivel joint packing(1)
Performance reduction of hydraulic pump Replace hydraulic pump(1)
Table 40. Rough travel

Cause Remedy
Excessively tightened track Adjust to proper tension
Stone or foreign matter caught in track Remove stone or foreign matter
Defective valve Repair valve or replace(1)
Air in travel motor Refill with oil
Table 41. Crooked travel

Cause Remedy
Left and right tracks are not equally tightened Bleed air from left and right, adjust tracks to equal tension
Performance reduction of hydraulic pump Replace hydraulic pump(1)
Oil leakage inside control valve Replace valve housing assembly(1)
Swivel joint packing damage Replace swivel joint packing(1)
Loose lever link Adjust
82 9813/0400-2 82
Routine Maintenance
Troubleshooting
Slew
Table 42. Insufficient slew force
Cause Remedy
Performance reduction of slew motor Replace slew motor(1)
Thermal seizure of slew shaft Supply grease or replace the slew shaft(1)
Table 43. Idle slew during slew braking

Cause Remedy
Low setting of brake valve Adjust the pressure(1)
Clogged valve Wash the valve(1)
Internal oil leakage of control valve Repair or replace valve assembly(1)
Table 44. Idle slew during slew stopping

Cause Remedy
Low setting of brake valve or port relief Adjust the pressure (1)
Clogged valve Wash the valve(1)

Internal oil leakage of control valve Repair or replace valve assembly(1)
Table 45. Abnormal noise during slew

Cause Remedy
Air in slew motor Refill with oil
Insufficient greasing of slew bearing Add grease
Hydraulic ram
Table 46. Insufficient force of hydraulic ram
Cause Remedy
Low pressure setting for the relief valve Adjust the pressure(1)
Oil leakage inside the hydraulic ram Replace the ram seals(1)
Damage of the hydraulic ram or rod Replace the hydraulic ram or rod(1)
Oil leakage inside the control valve Repair or replace the valve assembly(1)
Table 47. Oil leakage outside the hydraulic ram

Cause Remedy
Defective hydraulic ram seals Replace hydraulic ram seals(1)
Hydraulic cylinder rod damage* Replace hydraulic ram rod(1)
83 9813/0400-2 83
Routine Maintenance
Troubleshooting
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84 9813/0400-2 84

Section 3: Service Manual - JS200, JS140 & JS205

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Section 3

3-0 9813/0400-2 3-0

Contents Page No.

Contents Page No.

Introduction Owner/Operator Support

Remember, if your machine has been correctly

Fit for Purpose Tests for Lifting

All lifting equipment (for example forks, lifting hooks and

This may be needed every six months or at least annually

Check with your local JCB distributor for further advice.

Obtaining Replacement Parts

If you use non-genuine JCB parts or consumables, then

A Parts Book for your machine is available from your JCB

The data plate also shows the serial numbers of the

Health and Safety

Lubricants The collection and disposal of used oil should be in

It is most important that you read and understand this Handling

4 Don't keep oily rags in pockets.

5 Wash dirty clothing before re-use.

6 Throw away oil-soaked shoes.

First Aid - Oil

In the case of eye contact, flush with water for 15 minutes.

If oil is swallowed do not induce vomiting. Get medical

In the case of excessive skin contact, wash with soap and

Absorb on sand or a locally approved brand of absorbent

Extinguish oil and lubricant fires with carbon dioxide,

Battery electrolyte contains sulphuric acid. It can burn

When reconnecting, fit the positive (+) lead first.

A289260-1 Gets onto your skin

Note operating instructions.

Introduction How to Use the Service Schedules

To prevent anyone starting the engine, remove the

Apart from the daily jobs, the schedules are based on

Every 10 Hours = Daily

Pre Start Cold Checks, Service Points and Fluid Levels

Operation 10 50 250 500 1000 2000 4000 5000

Operation 10 50 250 500 1000 2000 4000 5000

Operation 10 50 250 500 1000 2000 4000 5000

Operation 10 50 250 500 1000 2000 4000 5000

Functional Test and Final Inspection

Operation 10 50 250 500 1000 2000 4000

Operation 10 50 250 500 1000 2000 4000

 Check oil level and top up as required

Table 2. Fuel System

Table 3. Hydraulic System

Fluids, Lubricants and Capacities

Item Lubricant International Specification Capacity

Item Lubricant International Specification Capacity

Item Lubricant International Specification Capacity

Engine Lubrication Chart

Use according to ambient temperature °C (°F)

Hydraulic Oil Chart

Use according to ambient temperature °C (°F)

JCB HYDRAULIC FLUID 32, ISO VG 32

JCB HYDRAULIC FLUID 46, ISO VG 46

JCB HYDRAULIC FLUID 68, ISO VG 68

Typical Lubrication Chart P Hydraulic tank air breather

Table 6. Icon Definitions

Engine oil change

Engine oil filter change

Engine coolant change

Fuel (diesel) When using bio-degradeable oil

When using in wet or severe